Wooden Stormtrooper Head




Are you a big fan of Star Wars? Do you like DIY and wooden object? Don't look further i have the project for you !

I'll show you how to creat a 3D wooden stromtrooper head really easily with simple tools and without any particular skills.

Are you ready?

May the force be with you!


-Polywood 5mm of thickness

-Glue in spray or any type of glue will do the work

-A4 Printer

-Scroll saw

- Wood glue

-Wood dowels 1cm or smaller diameter (optional)

-Sand paper

- Primer,paint, varnish (optional)

Step 1: The Software

As i said we're gonna create a 3D object by using stacked slices of wood. And to make this possible you have two options :

-being very talented and do it without any help

-by being clever and using the 123Dmake.

If you go times to times on instructable you've already seen this powerful tool that decomposes any 3D object into different slices.

Just for information, you can find below some really good instructables based on this software :


https://www.instructables.com/id/Star-Wars-Stormtro... (in fact i've found this one when i was writing this tutorial)

and more and more...

The file is found on thingiverse : http://www.thingiverse.com/thing:362947

Final size: 19.2x19.7x20 cm

Wood thickness = 0.5cm // Very important parameter ! If you choose another thickness you have to change the parameter in the software. The thicker it is, the less definition you have)

Step 2: Preparing the Slices

If you want to make modifications like remove the dowels holes, changing the size, the thickness of the materials or other you'll have to use the software but if you don't, you can use the file provided in this step

Then you print it on A4 paper and glue it on wood

Step 3: Scrollsaw for Ever!

Here we go for less 2h of cutting

BE CAREFULL YOU LL USE DANGEROUS OBJETS so be sure to wear all the safety equipements recommanded for your scrollsaw.

To make the assembly process easier for later, write on each slides the number provided by the software.

Step 4: Glue Glue Glue

Once you have all your pieces you can now make holes as indicated in order to put the dowels.

Sooo the process is really easy:

you take the number one glue it with the number two and again and again.

If you have choosen to work with the dowels you can put them in the holes and the alignement will be way easier.

And normally if you are a good padawan you'll obtain a wonderful stromtrooper head

Step 5: Finishing

To have a perfect object you'll have to sand it

First a big grain sand paper (80,100)

and then finishing sand paper (500,1000)

You just want to smooth it and have an homogenous surface so don't try to sand it to much.

Tadaaaaaa you're done

You can paint it if you want (as i did)

But be sure to apply 2 or 3 primer coats before adding the paint cause we used a lot of wood glue and it may leave some ugly marks.

I also add some varnish to protect it.

Thanks for reading ;)



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8 Discussions

Glo0myrufus the dog

Reply 2 years ago

I used dowels with 5mm of diameter. For the length i kept them really long in order to align everything easily and when i reached the top i cut them. Normally on the plans you will see some parts without the pre-made holes that's mean you have to cut the dowels when you have to glue these parts. Finally, the dowels are just here to help you to align the parts not to give strengh to the sculpture so the size doesn't really matter as long as the holes coresponding to your dowels' size.


2 years ago

any chance you can trace the slices to full size on an 8.5x11 sheet? i don't have a 3d cutter but would love to do this on a scroll saw.

1 reply

Reply 2 years ago

I'm not sure to fully understand your question, because the file i provided is made to be printed on a 8.5x11 sheet and i made mine with a scrollsaw so it won't be any problem for you. But if you mean that you want to do the same but with a full size helmet like in the movie, the problem will be that the software won't allow to have one slice divided on multiple pages ('cause of course it won't fit on a 8.5x11 sheet) so if you really want a full size one you'll have to print it on a bigger sheet format and then cut it with your scroll saw. I hope i answered to your question.


2 years ago

Super :) le mienne je vai surement mettre du plâtre dessus.

1 reply

Reply 2 years ago

Pour avoir une version lisse du stormtrooper je suppose. J'aimerai bien voir la photo une fois le projet fini. Ca va surement valoir le détour!


2 years ago

This is done so well! Thanks for sharing, I can't wait to see what other projects you come up with!

1 reply

Reply 2 years ago

Thanks a lot! I'm currently working on a lot of projects so i'm pretty sure other instructables will follow